Single trench repair method with etched quartz for attenuated phase shifting mask

ABSTRACT

In accordance with the objectives of the invention a new method is provided for the repair of an attenuated phase shifting mask having a contact pattern. The invention etches a single trench in the quartz substrate of the phase shifter mask and removes the impact of a void in the phase shifter material. Alternatively, the invention provides for first conventionally restoring the original dimensions of a contact hole in which a pinhole is present and then etching a single or a double trench in the exposed substrate of the restored contact opening.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No. 10/755,500, filed Jan. 12, 2004, now U.S. Pat. No. 7,157,191.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The invention relates to the fabrication of integrated circuit devices, and more particularly, to a method of creating an attenuated phase shifting mask by methods of repair thereof, whereby effects of pinholes are removed.

(2) Description of the Prior Art

During and for the fabrication of semiconductor devices optical projection tools are an integral part of the optical lithography technology that is fundamental to the creation of semiconductor devices and devices features. The optical projection tools conventionally contain an electromagnetic light source, a configuration of lenses and an optical projection mask that contains a replica of the image that is to be created. The image of the mask is, with the interference and the help of the configuration of lenses, projected onto the surface over which the image contained in the mask is to be created.

Semiconductor device improvements are traditionally and consistently achieved by sharp reductions in device feature dimensions, resulting in increasing device densities, which imposes on the supporting optical lithography technology the need for a continuing ability to provide images of smaller dimensions while maintaining image resolution.

Conventional photolithography masks are limited in this respect due to the increasingly smaller distance between adjacent light projections, which causes increased interference between closely spaced light projections. This has led to the development of phase-shifting masks, where effects of closeness of projecting light rays are cancelled by controlling the relative phase relationship between closely adjacent rays of light.

A phase shifting mask is provided with a layer of phase shifter material that is created in a pattern over the substrate of the mask. The patterned layer of phase shifter material causes the light that passes through the layer of phase shifter material to be out-of-phase by 180° with respect to the light that passes through the substrate over which the patterned layer of phase shifter material has been created. This results in a corrective action between the light that passes through the transparent substrate of the phase shifter mask and the light that passes through the layer of phase shifter material, this corrective action allowing further reductions in the images that are created using the phase shifter mask. Optionally, a phase shifter mask may also be provided with a patterned layer of opaque material such as chrome to further enhance the mask application.

Phase shifting masks are generally created using methods of photolithography. These methods at times lead to the introduction of fabrication defects in the surfaces of the created mask. For a phase shifter mask to be operational, especially considering the deep-submicron device features that must be created using the phase shifter mask, surface irregularities, such as voids occurring in a layer of phase shifter material, must be prevented or corrected if present. Any surface irregularity that occurs in any of the layers of the phase shifter mask, including the substrate of the phase shifter mask, results in a disruption of the there-through transmitted light and therefore in an interruption of a coherent interaction between the phase controlled light that is transmitted through the phase shifter mask.

Cost considerations relating to the creation of phase shifter masks lead to the need for repairing phase shifter masks that show any defects that may negatively affect the desired performance characteristics of the phase shifter mask. The invention addresses this concern and provides a method for the repair of attenuated phase shifter masks with a contact pattern.

U.S. Pat. No. 6,159,641 (Baume et al.) shows a method for repairing masks.

U.S. Pat. No. 6,016,357 (Neary et al.) discloses a method to repair PSMS.

U.S. Pat. No. 6,114,073(Yang) shows a method to repair PSMS.

U.S. Pat. No. 5,272,024 (Lin) discloses a structure and method for PSM repair.

U.S. Pat. No. 6,361,904 B1 (Chiu) shows a method for repairing the Shifter Layer of an alternating phase shifter mask.

SUMMARY OF THE INVENTION

A principle objective of the invention is to repair an attenuated phase shifting mask in a cost-effective manner.

Another objective of the invention is to repair an attenuated phase shifting mask without impairing operational phase shifting requirements of the mask.

Yet another objective of the invention is to repair an attenuated phase shifting mask that is independent of the wavelength for which the mask is designed and used.

In accordance with the objectives of the invention a new method is provided for the repair of an attenuated phase shifting mask having a contact pattern. The attenuated phase shifting mask is frequently used for the creation of contact holes or via openings and as such has a surface area of no phase shift and a surface area of 180° phase shift. Conventionally, when a surface defect such as a pinhole occurs in the layer of phase shifter material of an attenuated phase shifter mask, an opaque material is deposited over the pinhole. This opaque material however interrupts the desired and conventional operational characteristics of light transmission of the attenuated phase shifter mask. To avoid such an interruption, the invention etches a single trench in the surface of the quartz substrate of the phase shifter mask and removes the impact of a void in the phase shifter material. Alternatively, the invention provides for first conventionally restoring the original dimensions of a contact hole in which a pinhole is present and then etching a single or a double trench in the exposed substrate of the restored contact opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 a through 1 c highlight conventional methods of repairing a pinhole in a layer of phase shifter material.

FIGS. 2 through 5 highlight characteristics of phase shifting and light transmission for various combinations of deposition of opaque material and the creation of single and double trenches etched in the surface of the quartz substrate of the attenuated phase shifter mask.

FIGS. 6 a and 6 b show a normal attenuated phase shifter mask in which no pinhole is present.

FIGS. 7 a and 7 b show the occurrence of a pinhole in a contact opening.

FIGS. 8 a and 8 b show the conventional repair of a pinhole by depositing a layer of material around the perimeter of a contact opening in which the pinhole is present.

FIGS. 9 a and 9 b show a first repair of the invention by providing a single trench etch, in the exposed surface of the substrate (of the attenuated phase shifter mask) of the contact opening in which the pinhole is present.

FIGS. 10 a and 10 b show a second repair of the invention by providing a double trench etch in the exposed surface of the substrate (of the attenuated phase shifter mask) of the contact opening in which the pinhole is present.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

First are highlighted a number of statements of purpose that relate to the invention:

-   1. attenuated phase shifter masks are used for the patterning of     layers of contact openings -   2. conventionally, a commercial repair apparatus is used to deposit     an opaque material over a pinhole defect in a layer of phase shifter     material; this layer of opaque material however is in the     application of a phase shifter mask equal to an opaque layer, such     as a layer of chrome, and does therefore not provide a phase shift     of 180 degrees to light passing through the attenuate phase shifter     mask -   3. if the surface of a quartz substrate is etched, the phase     shifting function of the attenuated phase shifter mask is maintained     around the perimeter of the contact openings, and -   4. it is the observed conclusion of the invention that, in order to     repair a pinhole defect in a contact area, a single trench etched in     the surface of the quartz substrate can be created such that a phase     shift of 180 degrees can be provided to light passing through the     attenuated phase shifter mask.

A conventional method of repairing a pinhole over the surface of a quartz substrate, which is used as the substrate for an attenuated phase shifter mask, is first highlighted using FIGS. 1 a through 1 c for this purpose.

The cross section that is shown in FIG. 1 a shows a substrate 10, conventionally comprising quartz, over the surface of which a layer 12 of phase shifter material, such as MoSiON, has been deposited. The layer 12 of MoSiON has been patterned and etched, creating an opening 11 through the layer 12 of MoSiON, exposing the quartz substrate 10. The phase shifting material 12 provides a 180° phase shift to the light that passes through this layer 12, the phase of the light that passes through the quartz substrate 10 without passing through the layer 12 of phase shifter material is not affected and therefore has a 0° phase shift.

Pinhole 14 in the layer 12 of phase shifter material must be repaired, a repair that conventionally is performed by, as shown in the cross section of FIG. 1 b, depositing a small amount 16 of opaque material over the pinhole 14. This method has a number of disadvantages since the opaque material 16 acts as a deposition of chrome and therefore affects the light transmission characteristics of the layer 12 over which the opaque material 16 is deposited.

Some of the important parameters of light transmission and phase shifting that are provided by an attenuated phase shifter mask are now highlighted, using parameters that have been highlighted in FIG. 1 a for this purpose, as follows:

-   -   for regions 18, which are the regions of the attenuated phase         shifter mask underlying the opening 11 created through the layer         12 of phase shifter material, the light transmission of the         light provided by light source 13 is about 100%, the phase shift         that is introduced to this light is about 0°, and     -   for regions 20 and 22, underlying the patterned and etched layer         12 of phase shifter material, these parameters are: light         transmission of about 6%, phase shifting of about 180°.

From the cross section that is shown in FIG. 1 b, it can be seen that these characteristics are disturbed for region 24, underlying the deposited layer 16, where for region 24 the light transmission has been reduced while the phase shift is difficult to predict.

As a further demonstration of the repair that is conventionally performed to repair a pinhole in the layer of phase shifter material, FIG. 1 c shows a cross section wherein the phase shifter material 12 has been symmetrically removed around the perimeter of the contact opening 11. The removed phase shifter material has been replaced with opaque material 16′. The replacement opaque material 16′ is known to peel from the surface of the substrate 10 over which it has been deposited.

To avoid the above indicated negative effects that are introduced by conventional methods of repairing a pinhole or any other opaque deficiency over the substrate 10 of an attenuated phase shifter mask, the invention provides for etching a single trench into the substrate in areas surrounding the pinhole.

Comparisons of light transmission and phase shifting characteristics are first made for a number of configurations of quartz mask and thereover deposited layers of opaque material, using FIGS. 2 through 6 for this purpose.

Referring first to the cross section shown in FIG. 2, this represents a normal attenuate phase shifter mask and is used to highlight the relation between phase shift and light transmission for the various surface regions of the conventional attenuated phase shifter mask.

Specifically highlighted in the cross section of FIG. 2 are:

-   -   10, the transparent substrate of the attenuated phase shifter         mask, typically comprising quartz     -   12, the patterned and etched layer of phase shifter material,         typically comprising MoSiON; other phase shifter materials that         can be applied are CrO, ZrSiO₃ or SiON     -   11, the opening created through the layer 12 of phase shifter         material, exposing substrate 10     -   18, the region of the substrate 10 that aligns with opening 11,         ight passes through the attenuated phase shifter mask confined         by region 18, a 0° phase shift is experienced by the light that         passes through the attenuated phase shifter mask that is bounded         by opening 11     -   regions 20 and 22, phase shift about 180°, about 6% of the         incident light that strikes the surface of layers 12 passes         through these layers.

Referring now to the cross section that is shown in FIG. 3, there is shown:

-   -   10, the transparent substrate of the attenuated phase shifter         mask, typically comprising quartz     -   20, the patterned and etched layer of opaque material     -   21, the opening created through the layer 20 of opaque material,         exposing substrate 10     -   22, the region of the substrate 10 that aligns with opening 21,         100% light passes through the attenuated phase shifter mask         confined by region 22, a 0° phase shift is experienced by the         light that passes through the attenuated phase shifter mask that         is bounded by opening 21     -   regions 24 and 26, phase shift is difficult to control and         predict, no incident light passes through the patterned layer         20.

Referring now to the cross section that is shown in FIG. 4 which shows a single trench etched in the surface of the quartz substrate, there is shown:

-   -   10, the transparent substrate of the attenuated phase shifter         mask, typically comprising quartz     -   20, the patterned and etched layer of opaque material     -   31, an opening created through the layer 20 of opaque material,         exposing the surface of substrate 10     -   33, a single trench etched in the surface of substrate 20     -   regions 34 and 36, phase shift is difficult to control and         predict, no incident light passes through layers 20     -   regions 35 and 37, phase shift is zero, incident light passes         100% through the substrate 10     -   regions 32, phase shift 180 degrees, incident light passes 100%         through the substrate 10.

Referring now to the cross section that is shown in FIG. 5, which represents a double trench etched in the surface of the quartz substrate, there is shown:

-   -   10, the transparent substrate of the attenuated phase shifter         mask, typically comprising quartz     -   20, the patterned and etched layer of opaque material     -   41, an opening created through the layer 20 of opaque material,         exposing substrate 10     -   43, two trenches etched in the surface of substrate 20     -   regions 44 and 46, phase shift is difficult to control and         predict, no incident light passes through the patterned layer 20     -   regions 45 and 47, phase shift is 180 degrees, incident light         passes 100% through the substrate 10     -   region 42, phase shift 180 degrees, incident light passes about         100% through the substrate 10.

From the above a number of relevant observations can be made.

Relating to the single trench etch as shown in the cross section of FIG. 4, the following applies:

-   -   the etched area 33 is centered within the area of the contact         pattern, which is represented by opening 31 created through the         layer 20 of opaque material     -   the etched width of the etched single trench 33 approaches the         critical diameter of the contact area, exposed through the         opening 31     -   the etching of the quartz substrate is limited to a one-time         etch per contact area     -   the width of the etched trench exceeds the combined width of the         double trenches, which are shown in the cross section of FIG. 5     -   compared to the etching of the double trenches (43, shown in the         cross section of FIG. 5), the etching of the single trench (33,         shown in the cross section of FIG. 4) is easy to control in etch         width and etch location, and     -   relative to the deposited material 20 in combination with the         double trench etch, the single trench etch can be expected to         provided a larger repair window.

Relating to the double trench etch as shown in the cross section of FIG. 5, the following applies:

-   -   the etched area 43 is at the edge of the contact pattern, which         is represented by opening 41 created through the layer 20 of         opaque material     -   the etched width 45/47 of the etched single trench 43 is smaller         than the critical diameter of the contact area, exposed through         the opening 41, a suitable combined etch width 45/47 must be         experimentally determined     -   the etch of the double trenches 43 must be located around the         perimeter of the contact pattern 41     -   the width (45+47, shown in the cross section of FIG. 5) of the         etched double trenches 43 is less than the width (32, shown in         the cross section of FIG. 4) of the single trench 33     -   compared to the etching of the single trench 33, the etching of         the double trenches 43 is difficult to control in etch width and         etch location, and     -   the etch of double trenches 43 requires four steps of etch from         which follows that the creation of the double trenches 43 is a         process that is more difficult to control.

The single trench etch is therefore the preferred method of repairing a pinhole defect in the layer of phase shifter material as has been highlighted in the cross section of FIG. 4. That is the defect is assumed to be present in the region that is bounded by the opening 31 over the surface of the quartz substrate, the etch therefore removes the phase shifter material from this surface region and further etches into the surface of substrate 10, as has been highlighted in the cross section of FIG. 4 with the trench 33 etched into the surface of substrate 10. The phase relationships and light passing capabilities are, with the etch of trench 33, modified as follows:

The phase shift of 180° is achieved by selecting the depth of the created trench 33 such that, for a given incident light wavelength, an appropriate amount of quartz is removed. The light passing through the remaining layer of quartz underlying the created trenches can be provided with a phase shift of 180° in this manner.

For instance, for an incident light wavelength of 248 nm, the thickness of the quartz underlying the created trench must be about 238.5 nm. For an incident light wavelength of 193 nm, the thickness of the quartz underlying the created trench must be about 172.3 nm.

The following can be concluded:

-   -   for proper operation of a phase shifter mask, capabilities of         light transmission and phase shifting must be controlled     -   in conventionally repairing a pinhole or a void in the phase         shifter material of a phase shifter mask, the pinhole is covered         with an opaque material; where previously this region of the         phase shifter material has about 6% light transmission and 180         degree phase shift, the repaired region has 6% light         transmission and unknown degree phase shift     -   by removing the phase shifter material that contains the pinhole         or void and by in addition etching into the surface of the         quartz substrate, the effectiveness of the phase shifter         material is not altered since, see FIG. 4 for the single trench         etch, the required characteristics of 100% light transmission         and 0 degrees phase shift are maintained for surface areas 35         and 37 while the etch for single trench 33, surface area 32, the         light transmission characteristics through this surface are to         still 100% light transmission but now having, as determined by         the depth of the trench 33, a 180 degree phase shift.

This latter alteration of the contact region, bounded by opening 31, does not detract from the functionality of the contact surface. The exposure (of 100% light transmission) remains in effect over the entire contact area while the light transmitted through region 32 of the quartz substrate has a not detrimental phase shift of 180 degrees.

The contact region will continue to be exposed (in light intensity) as desired, the fact that the light within the area of exposure now has a phase shift of zero degrees and a phase shift of 180 degrees there-within does not affect the exposure of the contact area. It would, if beneficially applied, further minimize negative effects of light interference within the exposed contact area.

For further clarification and extension of the invention, FIGS. 6 a through 10 b are presented.

Shown in FIG. 6 a is a cross section of a substrate 10 of an attenuated phase shifter mask over which a patterned layer 50 of shifter material has been created. Openings 51 created through the layer 50 of phase shifter material are normal contact openings for pattern exposure by incident light 56. FIG. 6 b shows a top view corresponding to the cross section of FIG. 6 a, the cross section shown in FIG. 6 a has been taken along the line 6 a-6 a′ shown in FIG. 6 b. It is clear that the FIGS. 6 a and 6 b relate to a normal pattern, that is a pattern in which no pinhole defect is present.

Shown in FIG. 7 a is a cross section of a substrate 10 of a attenuated phase shifter mask over which a patterned layer 52 of shifter material has been created. Opening 51 created through the layer 52 of phase shifter material is a normal contact opening for pattern exposure by incident light 56. Opening 53 created through the layer 52 of phase shifter material is a contact opening in which a pinhole is present, as is obvious from the deformed and considerably larger diameter of opening 53 when compared with the cross section of opening 51. FIG. 7 b shows a top view corresponding to the cross section of FIG. 7 a, the cross section shown in FIG. 7 a has been taken along the line 7 a-7 a′ shown in FIG. 7 b.

Referring now to FIGS. 8 a and 8 b, therein is shown how a pinhole is conventionally repaired by deposition of an opaque material 54 around the perimeter of opening 53, restoring the cross section of opening 53 to a cross section 53′, which is equal to a cross section of the normal contact opening 51.

As has previously been pointed out, the repaired contact opening 53′ has, after the highlighted repair has been completed by the addition of layer 54, lost the phase shifting function while at the same time the depth of focus and the process window of the opening 53′ is smaller than the normal contact opening 51.

FIG. 8 b shows a top view corresponding to the cross section of FIG. 8 a, the cross section shown in FIG. 8 a has been taken along the line 8 a-8 a′ shown in FIG. 8 b.

Referring now to FIGS. 9 a and 9 b, there is shown how, in the structure that has previously been discussed using FIGS. 8 a and 8 b, a single trench 58 has been etched into the surface of substrate 10 where the substrate 10 is exposed in opening 53′, creating the opening 60 which comprises the single trench etch 58. For this method of repairing the pinhole 53, as shown in FIGS. 9 a and 9 b, the results are that the contact created by the repaired opening 60 provides the required phase shifting function while the depth of focus and the process window of the opening 60 are the same as the normal contact opening 51.

FIG. 9 b shows a top view corresponding to the cross section of FIG. 9 a, the cross section shown in FIG. 9 a has been taken along the line 9 a-9 a′ shown in FIG. 9 b.

The etch of double trenches is shown in FIGS. 10 a and 10 b, where in the structure that has been discussed using FIGS. 8 a and 8 b, the double trenches 62 have been etched into substrate 10 where this substrate is exposed in opening 53′, creating the opening 60′, which comprises the double trench etch 62. The area highlighted as area 64 is the area of the substrate 10 that is surrounded by the double trenches 62.

For this method of repairing the pinhole 53, as shown in FIGS. 10 a and 10 b, the results are that the contact created by the repaired opening 60′ provides the required phase shifting function while the depth of focus and the process window of the opening 60′ is the same as the normal contact opening 51.

FIG. 10 b shows a top view corresponding to the cross section of FIG. 10 a, the cross section shown in FIG. 10 a has been taken along the line 10 a-10 a′ shown in FIG. 10 b.

The cross sections and top views that are shown in FIGS. 6 a through 10 b highlight:

-   -   a normal attenuated phase shifter mask in which no pinhole is         present, FIGS. 6 a and 6 b     -   the occurrence of a pinhole in a contact opening, FIGS. 7 a and         7 b     -   the conventional repair of a pinhole, FIGS. 8 a and 8 b, by         depositing a layer of material around the perimeter of a contact         opening in which the pinhole is present     -   providing a single trench etch, FIGS. 9 a and 9 b, in the         exposed surface of the substrate (of the attenuated phase         shifter mask) of the contact opening in which the pinhole is         present     -   providing a double trench etch, FIGS. 10 a and 10 b, in the         exposed surface of the substrate (of the attenuated phase         shifter mask) of the contact opening in which the pinhole is         present.

Although the invention has been described and illustrated with reference to specific illustrative embodiments thereof, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in the art will recognize that variations and modifications can be made without departing from the spirit of the invention. It is therefore intended to include within the invention all such variations and modifications which fall within the scope of the appended claims and equivalents thereof. 

1. A repaired attenuated phase shifter mask, comprising: an attenuated phase shifter mask, the attenuated phase shifter mask comprising a transparent substrate over which a patterned layer of phase shifter material has been created; a defective area of the phase shifter material having been identified; the phase shifter material having been removed from the defective area; opaque material having been deposited on the defective area of the attenuated phase shifter mask; and a single trench having been etched into the transparent substrate aligned with the defective area to provide a phase shift angle being about 180 degrees, the trench location and dimensions comprising an exposure pattern.
 2. The repaired attenuated phase shifter mask of claim 1, the transparent substrate comprising quartz.
 3. The repaired attenuated phase shifter mask of claim 1, a depth of the single trench being about 238.5 nm for an exposure wavelength of 248 nm.
 4. The repaired attenuated phase shifter mask of claim 1, a depth of the single trench being about 172.3 nm for an exposure wavelength of 193 nm.
 5. The repaired attenuated phase shifter mask of claim 1, wherein said attenuated phase shifter mask is for contact layer patterning.
 6. A repaired attenuated phase shifter mask, comprising: an attenuated phase shifter mask, the attenuated phase shifter mask comprising a transparent substrate over which a patterned layer of phase shifter material has been created; a defective area of the phase shifter material having been identified; the phase shifter material having been removed from the defective area; and a double trench having been etched into the transparent substrate of the attenuated phase shifter mask aligned with the defective area to provide a phase shift angle, wherein the double trench is located at an edge of an exposure pattern, wherein the double trench further has dimensions being smaller than dimensions of the exposure pattern.
 7. The repaired attenuated phase shifter mask of claim 6, the substrate comprising quartz.
 8. The repaired attenuated phase shifter mask of claim 6, a depth of the double trench being about 238.5 nm for an exposure wavelength of 248 nm.
 9. The repaired attenuated phase shifter mask of claim 6, a depth of the double trench being about 172.3 nm for an exposure wavelength of 193 nm.
 10. The repaired attenuated phase shifter mask of claim 6, the phase shift angle being about 180 degrees.
 11. The repaired attenuated phase shifter mask of claim 6, wherein said attenuated phase shifter mask is for contact layer patterning.
 12. A repaired attenuated phase shifter mask, comprising: an attenuated phase shifter mask, the attenuated phase shifter mask comprising a transparent substrate over which a patterned layer of phase shifter material has been created; a defective area of the phase shifter material having been identified; the phase shifter material having been removed from the defective area; opaque material having been deposited on the defective area; and a double trench having been etched into the transparent substrate of the attenuated phase shifter mask aligned with the defective area to provide a phase shift angle, wherein the double trench is located at an edge of an exposure pattern, wherein the double trench further has dimensions being smaller than dimensions of the exposure pattern.
 13. The repaired attenuated phase shifter mask of claim 12, the substrate comprising quartz.
 14. The repaired attenuated phase shifter mask of claim 12, a depth of the double trench being about 238.5 nm for exposure wavelength of 248 nm.
 15. The repaired attenuated phase shifter mask of claim 12, a depth of the double trench being about 172.3 nm for exposure wavelength of 193 nm.
 16. The repaired attenuated phase shifter mask of claim 12, the phase shift angle being about 180 degrees.
 17. The repaired attenuated phase shifter mask of claim 12, wherein said attenuated phase shifter mask is for contact layer patterning. 